Method of making an intricate free-form cast metal art object

ABSTRACT

A unique free-form metal art object is manufactured by a casting method such that it is highly practical and economical to engage in mass-production techniques without impairing the uniqueness or beauty of each casting. The method comprises preparing a bed of pieces of ice, and then rapidly pouring molten metal onto such bed. The molten metal partially melts the ice, and gravitates downwardly through the interstices between the ice pieces to thus create, upon solidification, the free-form art casting having great beauty and individuality. The temperature of the molten metal, the amount, composition and purity of the metal, the size of the bed and the sizes and shapes and positions of the ice pieces making it up, are controlled in a predetermined manner which causes the general characteristics of the castings to be of certain desired types, but does not militate against the one-ofa-kind nature of each and every individual casting.

[ Dec. 17, 1974 METHOD OF MAKING AN INTRICATE FREE-FORM CAST METAL ART OBJECT [76] Inventor: Thomas W. Landig, 1136 Westmoreland Cir., Walnut Creek, Calif. 94596 [22] Filed: Dec. 3, 1973 21 Appl. No.: 421,097

[52] US. Cl 29/527.5, 29/160.6, 29/183, 29/423, 29/527.6, 29/DIG. 30, 164/132,

[51] Int. Cl 322d 23/08 [58] Field of Search 29/183, 160.6, 527.5, 527.6, 29/DIG. 30, 423, 527.3; 164/34, 36, 132;

249/61, 62; 264/D1G. 44; 425/DIG. 12

FOREIGN PATENTS OR APPLICATIONS France 249/62 Primary Exan1iner-C. W. Lanham Assistant ExaminerD, C. Reiley, 111 Attorney, Agent, or FirmRichard L. Gausewitz [57] ABSTRACT A unique free-form metal art object is manufactured by a casting method such that it is highly practical and economical to engage in mass-production techniques without impairing the uniqueness or beauty of each casting. The method comprises preparing a bed of pieces of ice, and then rapidly pouring molten metal onto such bed. The molten metal partially melts the ice, and gravitates downwardly through the interstices between the ice pieces to thus create, upon solidification, the free-form art casting having great beauty and individuality. The temperature of the molten metal, the amount, composition and purity of the metal, the size of the bed and the sizes and shapes and positions of the ice pieces making it up, are controlled in a predetermined manner which causes the general characteristics of the castings to be of certain desired types, but does not militate against the one-of-a-kind nature of each and every individual casting.

19 Claims, 4 Drawing Figures METHOD OF MAKING AN INTRICATE FREE-FORM CAST METAL ART OBJECT BACKGROUND OF THE INVENTION 1. Field of the Invention This invention relates to the field of metal casting, and of metal objects formed by casting.

2. Description of Prior Art It is well known that the pouring of substantial quantities of molten metal into water produces reactions which are frequently violent and even dangerous, such reactions involving the sudden generation of steam which tends to propel water and/or metal against adjacent people and objects. Furthermore, the solidified metal masses resulting from such pourings are generally unsatisfactory as art objects, in thatthere are excessive numbers of finely-pointed protrusions, etc.

The pouring of molten metal onto a flat surface is not characterized by the above dangers, but creates a product which is generally two-dimensional and not of high caliber as an art object. To achieve three-dimensional effects, which are extremely desirable from standpoints of both artistry and utility, the prior art has generally relied upon fixed-wall molds made of various materials. The objects cast in such molds cannot, however, be described as one-of-a-kind. Furthermore, there are (particularly when the shapes are intricate) major problems relating to the formation of the mold and/or the removal of the casting therefrom. These problems generate drawbacks relative to such factors as expense, production time, etc.

The following are all of the patents discovered in a novelty search of the present invention: 2,400,831; 2,480,048; 3,489,202; 3,374,824; 3,526,266.

SUMMARY OF THE INVENTION Applicant has now discovered that the above and other problems are eliminated by a method whereby molten metal is poured rapidly onto a bed comprising pieces of ice. Surprisingly, the rapid pouring of even relatively large amounts of molten metal onto such bed does not create violent generation of great amounts of steam, and does not result in dangerous conditions. This is true even in cases where there is a substantial amount of water in the ice bed.

The metal, as it flows downwardly between the ice pieces, assumes the shape of an intricate and beautiful three-dimensional art casting which may be used in a great variety of ways. Because the ice bed is never the same twice, each casting is uniquely different from each other casting. Because a large amount of the ice is melted during and after each pour, there is no difficulty in removing the casting from the bed.

Preferably, the method is so conducted that the resulting art object although often intricate does not have large amounts of fine, pointed protrusions, which may require removal (with much labor) in order to prevent injury to persons with whom it comes in contact. Instead of having numerous needle-like protrusions, the art casting has many relatively smooth and interestingly curved regions which are not dangerous.

Numerous factors are controlled in such manner that practical mass-production of beautiful free-form art castings is achieved without major amounts of finishing labor. These factors include the type, temperature and amount of metal, and the size and composition of the ice bed. Although the general character of the castings is thus maintained within reasonable limits commensurate both with beauty and with economy of production, there is never a case where any casting duplicates another.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is an isometric view showing the pouring of the molten metal onto the ice bed;

FIG. 2 is a cross-sectional view of a different embodiment, illustrating the use of a pouring mandrel and also showing the metal and ice therearound;

FIG. 3 shows a slamming mandrel which may be used to cause the casting to rest on a supporting surface at a desired angle; and

FIG. 4 is an isometric view of the finished casting.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT Referring to FIGS. 1 and 2, a bed 10 comprising a multiplicity of pieces 11 of ice is provided, being preferably confined within a suitable container such as the square container 12. To drain water from the ice bed 10, a valve 13 is provided at the extreme bottom region of the container.

- The pieces 11 of ice are so shaped and disposed that there are substantial interstices therebetween. ln accordance with the present method, molten metal is dumped rapidly onto the bed for flow downwardly through such interstices so that it will, upon solidification, form the unique, free-form art casting 14 best illustrated in FIG. 4.

The molten metal is shown at 16 in FIG. 1, being disposed in a ladle 17. in performing the method, the metal is dumped from the ladle 17 rapidly, but preferably not instantaneously so that there will be minimized splashing. As discussed below, the various factors are so regulated that the 'metal will flow downwardly through the spaces between the ice pieces for very substantial distances, creating beautifully-shaped stalactites 18. Normally, the art casting 14 is inverted after pouring and solidification, so that (as shown in FIG. 4)

the stalactites become stalagmites.

The molten metal 16 effects melting of substantial portions of the ice pieces, thus creating water which is readily drained off through valve 13. Such partial melting also simplifies removal of the casting from the ice bed, with minimized ice retention in the casting, so that much of the ice remaining in the bed may be reused (in the manner described below) for creation of another art casting. Any ice which is retained in the casting is allowed to melt completely and drains off as water.

The resulting art casting (FIG. 4) is highly intricate, three-dimensional, and characterized by the presence of numerous interestingly-rounded regions, having some relatively thin areas and other large and contoured sections. When the method is performed in the preferred manner, as indicated below, there is a relative absence of sharp protrusions which may be dangerous to persons handling the casting. Any such dangerous regions are, however, readily removed during the finishing portion of the method.

The most desirable art castings formed in accordance with the present method have open shapes and solid stalagmites 18, with smooth edges and corners. The less desirable castings have closed shapes, relatively flimsy stalagmites, sharp needles, sharp edges, and thin tinfoil" regions. Regardless of the type of casting, the finishing operations may include deburring, polishing, cutting or clipping, as well as bending and grinding steps. Flame deburring of sharp edges may be achieved by using a gas-oxygen torch to burn off tinfoil, needles, weak stalagmites and other undesirable regions. It is emphasized, however, that when the method is performed in its preferred manner, the amount and duration of such finishing operations are minimized, so that the resulting art casting may be created with a relatively small labor charge.

The present method is preferably employed using metals or metal alloys having relatively low melting points. For example, a highly desirable metal for use in the present method is aluminum, preferably aluminum having a purity in excess of 99.9 percent. Another metal which may be used, and which has a melting point even lower than that of aluminum, is zinc. Other examples of suitable metals are zinc-aluminum alloys. Numerous other aluminum alloys, such as alloys No. 356 and No. 5052, may be used (reference being made to Standard Handbook for Mechanical Engineers, by Baumeister and Marks, Seventh Edition, published by McGraw-Hill, at pages 6-85 and 6-87).

The temperature of the metal should be sufficiently high that it will penetrate the bed to a considerable depth before solidifying, but sufficiently low that there will be very little (if any) formation of sharp protrusions, points, etc. As an example of a preferred temperature range for aluminum (having a purity of at least 99.9 percent), the temperature of the molten metal 16 may be 1320 degrees F. plus or minus degrees F. Such a temperature range, for the relatively pure aluminum, has been found to produce consistently satisfactory results.

The amount of metal which is poured is also of major importance in determining the character, namely the overall characteristics, of the resulting art casting. To state one example, the casting of over six pounds of aluminum produces an art object having a very different character from that created by the casting of less than three pounds of aluminum.

Other major factors relating to the characteristics of the resulting art object are the makeup, composition and size of the ice bed 10. The bed preferably consists of ice cubes disposed in a random manner instead of being uniformly stacked. However, the ice may also (or alternatively) be present in the forms of cakes, crushed particles or lumps. One desirable cube shape has dimensions of 1 /2 inches by l /2 inches by inch, which may be made in a Whirlpool ice maker. The cubes preferably have rounded edges and should be free of frost. To accomplish both of the last-mentioned results, the cubes after removal from the icemaker may be sprayed with water which is then (preferably) drained off through the valve 13.

It is to be noted that relatively large ice pieces should be used for the larger castings, and relatively small pieces for the smaller ones.

The size of the ice bed 10 should, preferably, be sufficiently large that the metal will not contact the walls or bottom of container 12. It is to be understood, however, that unusual shapes may in some instances be achieved by permitting molten metal, at certain regions, to contact the container wall, in which event the wall is made of some suitable heat-resistant material. Although the pour is normally effected at the center of the bed 10, as shown in FIG. 1, it may in some instances be effected at one corner thereof in order to achieve unusual effects.

To achieve economy of operation. the ice which remains after each casting operation is not thrown out but instead is reused. More particularly, such residual ice is mixed with new cubes, or other new types of ice, to form a conglomerate.

Although the method is preferably employed with an ice bed 10 which is thoroughly drained of water, it may be desired in some instances to provide variations in the shape of resulting art casting by permitting a certain amount of water to remain in the bed. The water in the ice acts as a barrier to the metal, limiting the length of the stalagmites formed, and thus creating more compact shapes. Furthermore, the resulting art casting has many more needle-like portions which (as stated above) are normally not desired. It is emphasized that pouring molten metal into a bed comprising a mixture of ice and water is very different from pouring into water alone, one reason being that the ice operates to support the metal and thereby prevents it from dropping to the bottom of the container, and another important reason being that the ice tends to minimize the sudden generation of steam with resultant sometimes violent effects.

As one specific example of the present method, one pound of molten aluminum (having a purity of 99.9 plus percent) was heated to a temperature of 1320 degrees F. and placed in the ladle 17. The metal 16 was then dumped rapidly (as shown in FIG. 1) from the ladle 17 onto the central region of the bed 10 which was formed of a mass of randomly-disposed ice cubes each measuring 1 A inches by l k inches by inch. The metal rapidly solidified into the three-dimensional free-form art casting 14, which casting was removed from the bed immediately after solidification in order to minimize melting of the residual ice. The art casting was then suitably finish-worked in order to remove any undesired spikes, foil, etc.

ln some cases, it may be desired to provide one or more means to effect guiding and/or spreading of the molten metal in the ice bed, and/or to provide an opening through the resulting casting14. For example, a pouring mandrel 19 FIG. 2) may be mounted in the ice bed 10 and supported (preferably, not necessarily) on the bottom of container 12. The illustrated mandrel 19 has a rounded upper surface 21 in order to cause the molten metal to run off the mandrel end and into the ice bed. Mandrel 19 should be tapered and may be formed, for example, of steel, graphite, etc, being preferably not formed of the metal of which the art casting is made. When the pouring mandrel 19 is utilized, the casting has an opening which may be used for insertion of a candle or other object.

When the pouring mandrel 19 (FIG. 2) is used, it is often desirable to make use of a slamming mandrel 22 (FIG. 3) having a steel base 24. The size and shape of mandrel 22 is appropriately related to that of mandrel 19 in such manner that the art object 14, after being removed from ice bed 10 and then inverted, may be mounted on the mandrel 22 which then penetrates the opening resulting from the presence of the pouring mandrel 19. The object is then rapidly and forcefully slammed downwardly in order that the upper surface of base 24 will contact at least three downwardly extending protrusions on the casting l4 and cause the ends of such protrusions to lie in a single plane which is radial to the mandrel axis. These three ends are then employed to support the casting on a horizontal support surface, and to cause the candlestick (or other object) to be perpendicular to such support surface.

To create relatively large pieces, and unusual art forms, two or more of the art castings 14 may be welded or otherwise secured together. Inert-gas arc welding is preferable employed for this purpose, particularly when the castings are formed of aluminum. Furtherfore, various attachments such as candleholders, decorative elements, etc., may be welded to the castings in order to enhance their appearance and increase their functional value.

Other decorative operations which may be employed relative to the casting 14 include bright dippingfanodizing, painting, and plating. For example, the bright dipping may comprise dipping aluminum castings into a hot solution of nitric and phosphoric acids, thus achieving a bright finish. A matte finish is created, when desired, by means of a chemical dip or by grit blasting. The anodizing of aluminum castings, in various ways known in the art, permits the formation of surface coatings of various colors.

With zinc castings in particular, plating may be employed in order to improve the appearance. To state but one example, a coating of nickel may be provided on the zinc. In some cases, for expensive art objects, a coating of gold may be provided over the nickel.

A further manner of treating the castings 14 is to' paint them, as by use of powder paints such as epoxies applied by dipping in a fluidized bed. In addition, electrostatic spraying followed by baking (to polymerize the finish) may be employed.

Although (as stated above) the metal or metal alloy employed in the present process is preferably one having a relatively low melting point, for example aluminum or zinc, the method may also be employed with higher melting-point metals and alloys. These may include, to state but a few illustrations, copper, brass, bronze and even stainless steel.

it is also pointed out that certain metals, for example zinc, can be caused to solidify with a dendritic pattern which exposes certain crystallographic planes. These planes act as small mirrors" and give a highly reflective surface to the art object.

The resulting art products may be used in a vast number of ways. These may include desk pieces, paper weights, book ends, flower arrangers, decor in aquariums (in place of coral), fountains, etc. As indicated above, the art objects may also be associated with other objects. Some of these other objects may be candle and taper holders, lamps, coffee tables, chandeliers, frames, flower arrangers, pen and pencil holders, book ends, flower pot holders, etc.

The word ice is used in its ordinary sense, in the present specification and claims, to mean frozen water. The water may, however, contain impurities so long as they do not prevent freezing into solid ice. The ice then acts, as indicated above, as both a molding and quenching medium for the molten metal.

The word cubes" denotes those ice lumps which are made in conventional home refrigerators, which cubes are not necessarily square or even rectangular in shape.

The foregoing detailed description is to be clearly un' derstood as given by way of illustration and example only, the spirit and scope of this invention being limited solely by the appended claims.

What is claimed is:

1. A method of creatingan unique three-dimensional metal art casting having a variety of protrusions and open spaces, which method comprises:

a. providing a bed consisting essentially of a multiplicity of pieces of ice,

b. causing molten metal of relatively low melting point to flow through intervening regions between the pieces of ice in said bed, and

c. simultaneously permitting said metal to solidify to thus form the unique metal art casting.

2. A method of creating a unique three-dimensional metal art casting having a variety of protrusions and open spaces, which method comprises:

a. providing a bed consisting essentially of a multiplicity of pieces of ice,

b. heating a mass of metal of relatively low melting point until the metal is molten,

c. causing said molten mass to flow through the interstices between said pieces of ice, thereby effecting a certain degree of melting of said pieces,

d. permitting said molten mass to solidify in response to the transfer of heat from said mass to said pieces, and

e. removing said solidified mass from said bed and employing said mass as a unique three-dimensional metal art object.

3. The invention as claimed in claim 2, in which said method further comprises causing the ice pieces in said bed to be arranged in random manner as distinguished from uniformly.

4. The invention as claimed in claim 2, in which said method further comprises causing said pieces of ice to be ice cubes.

5. The invention as claimed in claim 2, in which said method further comprises causing said bed to consist of said ice pieces only, not pieces of other substances.

6. The invention as claimed in claim 2, in which said method further comprises causing said bed to be well drained of water.

7. The invention as claimed in claim 2, in which said method further comprises causing at least a substantial number of said ice pieces in said bed to be immersed in water. i

8. The invention as claimed in claim 2, in which said heating step comprises elevating the temperature of said molten mass to a value sufficiently high that said mass will penetrate relatively long distances through said interstices, but sufficiently low that there will not be excessive formation of thin needle-like protuberances.

9. The invention as claimed in claim 2, in which said method further comprises initiating said flow referred to in step c at the upper region of said mass, and then permitting the molten mass to flow downwardly through said interstices in response to gravitational forces.

10. The invention as claimed in claim 9, in which said step e includes inverting the solidified mass whereby the art object when in use has stalagmites which were stalactites when the mass was poured.

11. The invention as claimed in claim 2, in which said method further comprises providing said molten mass in a ladle, and dumping said metal from said ladle over a predetermined region of said mass at a rate which is 7 rapid, but insufficiently rapid to cause excessive splashl2.'The invention as claimed in claim 2, in which said metal is selected from a class consisting of aluminum, zinc, and zinc-aluminum alloys.

13. The invention as claimed in claim 2, in which said metal is aluminum.

14. The invention as claimed in claim 13, in which said aluminum is at least 99.9 percent pure.

15. The invention as claimed in claim 14, in which said method further comprises causing the temperature of said aluminum, immediately prior to said step c, to be in the range of l320'degrees F. plus or minus degrees F.

16. The invention as claimed in claim 2, in which said method further comprises varying the sizes and shapes of said pieces of ice, varying the size of said bed, and varying the amounts of metal employed, to thus change 8 the characteristics of the resulting castings.

17. The invention as claimed in claim 2, in which said 3 method further comprises working the resulting casting prises: a mass of metal having a variety of protrusions and open spaces,

said mass having been formed by causing molten metal of relatively low melting point to flow through the interstices in a bed consisting essentially of a multiplicity of pieces of ice, simulta-.

neously permitting said molten metal to solidify into the cast metal art object, and then removing said art object from said bed. 

1. A method of creating an unique three-dimensional metal art casting having a variety of protrusions and open spaces, which method comprises: a. providing a bed consisting essentially of a multiplicity of pieces of ice, b. causing molten metal of relatively low melting point to flow through intervening regions between the pieces of ice in said bed, and c. simultaneously permitting said metal to solidify to thus form the unique metal art casting.
 2. A method of creating a unique three-dimensional metal art casting having a variety of protrusions and open spaces, which method comprises: a. providing a bed consisting essentially of a multiplicity of pieces of ice, b. heating a mass of metal of relatively low melting point until the metal is molten, c. causing said molten mass to flow through the interstices between said pieces of ice, thereby effecting a certain degree of melting of said pieces, d. permitting said molten mass to solidify in response to the transfer of heat from said mass to said pieces, and e. removing said solidified mass from said bed and employing said mass as a unique thrEe-dimensional metal art object.
 3. The invention as claimed in claim 2, in which said method further comprises causing the ice pieces in said bed to be arranged in random manner as distinguished from uniformly.
 4. The invention as claimed in claim 2, in which said method further comprises causing said pieces of ice to be ice ''''cubes''''.
 5. The invention as claimed in claim 2, in which said method further comprises causing said bed to consist of said ice pieces only, not pieces of other substances.
 6. The invention as claimed in claim 2, in which said method further comprises causing said bed to be well drained of water.
 7. The invention as claimed in claim 2, in which said method further comprises causing at least a substantial number of said ice pieces in said bed to be immersed in water.
 8. The invention as claimed in claim 2, in which said heating step comprises elevating the temperature of said molten mass to a value sufficiently high that said mass will penetrate relatively long distances through said interstices, but sufficiently low that there will not be excessive formation of thin needle-like protuberances.
 9. The invention as claimed in claim 2, in which said method further comprises initiating said flow referred to in step c at the upper region of said mass, and then permitting the molten mass to flow downwardly through said interstices in response to gravitational forces.
 10. The invention as claimed in claim 9, in which said step e includes inverting the solidified mass whereby the art object when in use has stalagmites which were stalactites when the mass was poured.
 11. The invention as claimed in claim 2, in which said method further comprises providing said molten mass in a ladle, and dumping said metal from said ladle over a predetermined region of said mass at a rate which is rapid, but insufficiently rapid to cause excessive splashing.
 12. The invention as claimed in claim 2, in which said metal is selected from a class consisting of aluminum, zinc, and zinc-aluminum alloys.
 13. The invention as claimed in claim 2, in which said metal is aluminum.
 14. The invention as claimed in claim 13, in which said aluminum is at least 99.9 percent pure.
 15. The invention as claimed in claim 14, in which said method further comprises causing the temperature of said aluminum, immediately prior to said step c, to be in the range of 3120 degrees F. plus or minus 20 degrees F.
 16. The invention as claimed in claim 2, in which said method further comprises varying the sizes and shapes of said pieces of ice, varying the size of said bed, and varying the amounts of metal employed, to thus change the characteristics of the resulting castings.
 17. The invention as claimed in claim 2, in which said method further comprises working the resulting casting to remove burrs and other undesired regions.
 18. The invention as claimed in claim 2, in which said method further comprises decoratively coating or brightening the surfaces of the resulting casting.
 19. A free-form cast metal art object, which comprises: a mass of metal having a variety of protrusions and open spaces, said mass having been formed by causing molten metal of relatively low melting point to flow through the interstices in a bed consisting essentially of a multiplicity of pieces of ice, simultaneously permitting said molten metal to solidify into the cast metal art object, and then removing said art object from said bed. 